Arc welding system



pnl 7, 1953 n. c. GIRARD ARC WELDING SYSTEM Filed Feb. 24, 1949 for illustrative purposes only. The source I mai7 be connected by line switches II and a line contactor, shown generally at I2, to energize a primary winding I3 of a welding transformer that is shown, generally, at I5. The welding transformer I3 includes a secondary winding I5 whose open circuit voltage may be of the order of eighty to ninety volts. The line contacter I2 includes an operating winding I2w, normally closed contacts 20, whose function will be described hereinafter, and normally open contacts i217 and I2C. It will be observed that the contacts |21), when closed, serve to connect the primary winding I3 for energization to the source I when the switches Il are closed. Contacts I2C are provided to connect a capacitor IS across the primary winding I3 for power factor correction.

The secondary winding i5 of the welding transformer i4 may be connected by conductors I7 and I3 to supply current for maintaining a welding arc I3 between an electrode 25, which may be of the non-consumable type, and work 2l on which the welding operation is to be performed. An inert gas, such as argon, may be supplied through a conduit 22 around the electrode 20 and the arc I9 in accordance with conventional shielded arc welding practice.

Since the welding arc I5 is supplied from the secondary winding l5 of the welding transformer I4 with relatively low frequency alternating current, diiculty is encountered in striking and maintaining the arc. The tungsten electrode 25 should not touch the work 2l except to a very minor extent for it will be contaminated and interfere with proper operation. In order to assist instriking and maintaining the arc, provision is made for superimposing on it a current of a relatively high frequency. For this purpose frequencies in the band from 26.95 to 27.28 megacycles have been set aside tentatively. A frequency of 27.12 megacycles has been chosen from this permissible band of frequencies for stabilizing the operation of the arc i5.

The stabilizing high frequency is supplied to the arc I9 in close proximity thereto. For this purpose an inductor 23 is connected between the welding electrode 25 and the conductor I'I, as shown. The inductor 23 has terminals 2Q and 25. It will be noted that the terminal 24 is immediately adjacent the electrode 25 while the terminal 25 provides for connection to the Welding lead or conductor Il.

The stabilizing high frequency is applied across the inductor 23 by means of a co-axial cable that is shown, generally, at 25. It will be noted that the inner conductor 2'! of the co-aXial cable 25 is connected to the terminal 2li of the inductor 23 which is adjacent the electrode 25 and the arc I9. The outer conductor 2S of the co-axial cable 26 is connectedlto the other terminal 25 of the inductor 23. 1t will be understood that the length of the co-axial cable 26 is chosen with respect to the wave length of the stabilizing frequency employed so that the high frequency current is transmitted therethrough with a minimum of loss and a maximum of efficiency. Overheating of the co-axial cable 23 is avoided. At the same time sufficient power is available across the inductor 23 to provide the desired stabilizing eifect'on the arc I9.

lThe conductors 21 and 28 which comprise the co-axial cable 26 may be connected through capacitors 33 and 34 to an inductor 35. As illustrated, the connections between the capacitors 33 and 34 and the inductor 35 are variable in order to permit adjustment of the tuning as may be required. The inductor 35 forms a part of a self-rectifying self-excited high frequency generator which is indicated, generally, at 36. The inductor 35 has a center tap, as shown, which is connected through a radio frequency choke coil 3i to ground at 38.

The generator 35 includes a double triode electric valve 39 which is of known design and construction. Type SOLiTL has been found satisfactory for the purposes of the generator 36. It will be understood, however, that two separate single triode valves can be employed, if desired, in lieu of the double triode electric valve 39 illustrated.

The valve 39 includes an anode or plate 40 and a control grid 4I, these being connected, as shown, to the ends of the inductor 35. The valve 39 also includes a pair of hot cathodes 42 which may be heated by secondary windings 43 of a filament transformer, shown generally, at 44. which has a primary winding 45.

Any suitable means can be provided for energizing the primary winding 45. As shown, a switch 4S is employed for connecting the primary winding e5 for energization across a secondary winding el, operating at volts, which forms a part of a transformer, shown generally at 48. The transformer 43 has a primary winding 4S which may be connected for energization across the source I when the switches Il are closed. In addition the transformer 48 has a low voltage secondary winding 50 arranged, as indicated, to operate at about seven volts, and used for a purpose to be described presently.

As indicated, the generator 36 is of the selfrectifying type. In order to accomplish this radio frequency choke coils 55 interconnect the circuits to the hot cathodes 42 with a secondary winding 55 of a plate transformer that is indicated, generally, at 51. A primary winding 58 forms another part of the transformer 5l and it is arranged to be connected in a manner to be described presently for energization across the secondary winding l? of the transformer 43.

It is desirable that the high frequency generator 35 function only during the time that the arc IS is maintained between the electrode 2B and the work 2l. hood of radio interference since there is none when the generator 35 is not functioning and radiation is at a minimum when the arc I9 is being maintained. In order to initiate the generator 36 in operation when it is desired to strike the arc I9 a start relay, shown generally at 59, is provided. The start relay 59 includes an operating winding 59w, normally open contacts 59a and normally closed contacts 59h. The start relay 53 also may have normally open contacts 59o which, when closed, connect a resistor 5S in parallel with the winding 53u). The resistor 59' may be employed for the purpose of insuring that the relay 59 always will drop out at substantially the .same value of current flowing. through its energizing circuit when the welding electrode 20 is withdrawn from the work I9 preparatory to initiating subsequently the welding operation.

When the start relay 59 pulls a circuit is completed at contacts 59a, which will be traced hereinafter, for connecting the primary winding 5,8 of the transformer 51 for energization across the 110 volt winding 41 of the transformer 48. This serves to energize the plate circuit of the valve This reduces the likeli- 39'and causesk the high frequency generator 3S to radiate energy. In order to maintain the energizing circuit for the primary Winding 58 closed, a holding relay, shown generally at 6D, may be employed. rThis. relay includes an operating. winding tinoV and two sets' of normally open contacts an'd lib.

It is desir-able that the flow of gas through the conduit 2r takes'place only during the time that the weldingoperation is being performed. Further, it is' desirable to turn the gas on automatically and to turn it oir rather than to re-V quirethat this be done manually bythe operator. For this purpose a gas valve 63 maybe connected in the conduit 22 and a spring 64 may be provided for biasing it tov the closed position. The valve 63 may be opened by a lever 65 which may be fulcrumed at 6E and connected for operation to. anarmature 57 whose position Vis controlled by a winding 63. As will appear hereinafter, the. winding t3 is energized in response to the pulling of. the start relay 59 and it is maintained energizedby the holding relay B9.

At the termination of the welding operation bythe withdrawal of the electrode suihciently far from the work 2l so that no arc is maintained therebetween, it is desirable that the high frequency generator t cease to radiate, that the valvev E3 be closed and that the line contacter I2l be opened. In order to accomplish these functions in response to the change in load on the Weldinglcircuit represented by the conductors El and IS, time delay relay means, shown generally at'l, maybe employed. This relay means 'il inchicles a time delay relay, shown generally at l2, which comprises a heater element 'lh that may be connected, as shown, for energization acrossthe conductors l? and i8. The heater element '12h is placed alongside of a bimetallic strip 12cm which is arranged to close normally open contacts 12a when sufficient heat is applied to the bimetallic strip 'lbm by the heater 72h. This takes place when the open circuit voltage exists between the conductors ll and I8. It will be understood that, while the arc i9 is being maintained, the voltage across the secondary winding lof the transformerr l is of the order of. from twenty to thirty volts and the design.

and construction of` the time delay relay l2 is such that, when the heater element 72h is ener gized from this low voltage, suiiicient heat is .not

predetermined interval which, for example, mayV be of the orderY of iive seconds alter the welding arc` |9-has been extinguished. Cooperating with the time delay relay 'l2 is an auxiliary relay that is indicated, generally, at '13. It includes an operating winding 1311i and normally closed contacts 13a. When the contacts 12a of the time delay relay l2 are closed, the winding i310 isconnected for energization across the conductors I7 and I8 and, as a result, contacts 13a are opened to open theenergizing circuit Iorthe winding lwr of. the holding relay 6B, as will be described presently, tocause it to drop and perform thefuuc` tions indicated above. While the winding 73u) of the auxiliary relay 'E3 is illustrated as being connected for energization across the conductors l1 and I8, it will be understood that it may be connected for. energization to any suitable source such as that provided by the secondary winding 4l of the transformer et.` Also, .instead cfpro- 6,., viding normally open contacts 12a on they time delay relay 12, it may be provided with normally closed contacts and these contactsmay be connected in the circuit in lieu of the contacts "13a of the auxiliary relay 73. construction is employed, itis' unnecessary to use the auxiliary relay 13.

InV describing thevfunctioning of' the. system shown in the drawing, it will be assumed thatV the switches l l and 46 have been closed and that the line contactor l2 and relays 59 and 80 are inthe deenergized or dropped positions shown in the drawing. LAlso it will be assumed that the welding electrode2ll is out of contact with the work 2|. The impedance of the secondary wind'- ing l5 is high enough to prevent energization of` the winding Ew of the startrelay- 59 therei8, normally closed contacts 12a, and conductor la back to the secondary winding 50.

As soon as the operating winding Ew of the' start relay 59 is energized in the manner just described, the circuit to the operating winding lw of the line contactor 'l2 is opened at contacts 59h and at contacts 53a a circuit is completed for energizing the primary winding 58 of the plateV transformer 5l. This circuit may be traced from one terminal of the secondary winding 4l' through conductors d and 8|, primary winding 58, conductors B2 and 83, contacts 59a, conductors 84 and 85, back to the other terminal of the secondary winding lil. It will be observed that the operating winding Giiw of the holding relay G0 isv connectedk in parallel with the primary winding 53 of the transformer 5l. Also it will loe observed that the winding 66 which controls the opening of the valve 63 is connected by con-` ductors 8E and 8l in parallel with the primary winding 58. Accordingly, on closure oi the con'- tacts the windingv Sw and the winding 68 are energized simultaneously with the energiza-u tion or the primary winding 58. Accordingly, the valve 63 is opened and the inert gas liows through the conduit 22 around the electrode 2B.

v Nothing further happens until the operator withdraws the electrode 2t from the work 2| while maintaining it close thereto so that the are I9 now provided solely by the high frequency current from the generator 2S will continue. However, the previously traced circuit for energizing the operating winding ofthe start relay 59 is opened and this relay drops. Although contacts 59a of the start relay k5: are openedby ther dropping of this relay, the circuits for energizing the primary winding 56, ofthe Vtransformer 5?, theoperating winding Silw of the holding relay 6i), and the valve opening winding 68 are maintained energized through the closure of contacts Gta of the holding relay Eil. It will be observed that these .contacts Sta are connected in parallel with the contacts 59a through conductors 84 and S' and also conductors 83 and 88. It will be noted that the normally closed contacts 'lilav of the auxiliary relay i3. are. connected between the- When this `alternate.

accusaconductors 83 and 88 in this holding circuit so that, when the start relay 59 drops, the normally closed contacts 13a of the auxiliary relay 'I3 are connected in series with the contacts 63a of the holding relay 60.

The dropping of the start relay 59 completes a circuit at 59h for energizing the operating winding I2w of the line contactor I2. This circuit may be traced from one side of the secondary Winding 41 of the transformer d8 through conductor 80, contacts 6022, conductor 89, contacts 59h, operating winding |210, and conductor B to the other side of the secondary winding d'1.

The line contactor I2 now picks up and at contacts I2b and I2C closes the circuits for energizing the. primary winding I3 of the welding transformer VI v and connecting the capacitor I5 thereacross. Welding current now is induced in the secondary winding I5 of the welding transformer I4 and it ows through the conductors or welding leads I'I and I8 and the inductor 23 to provide the required current for maintaining the arc I9 to perform the Welding operation, the arc I9 now being stabilized by the superimposed high frequency from the generator 26.

Since the contacts I2a are opened when the line contactor I2 is in the operated or pulled position, no current can flow through the operating winding 59w of the start relay 59. As pointed out above, the voltage across the conductors I'I and I3 while the welding arc Is is being maintained is so low that the heater element I2h is notl energized sumciently to cause the bimetallic element 'I2bm to be flexed and close the contacts l2a. As long as the foregoing conditions exist and the electrode 20 is held close enough to the workqZI so that the welding arc isV maintained, the system continues to `function. as described.

When the operator wishes to terminate the welding operation,- he moves the electrode 2c suiciently far from the work 2l so that an arc cannot be maintained therebetween. Immediately the voltage between the conductors I'I and I8 is the open circuit voltage of the secondary winding i5. The heater element 12h now has sufficient current flowing through it so that, after the interval for which it has been set elapses, the bimetallic element 12cm is ieXed and contacts ia are closed. This completes the energizing circuit for the winding i310 of the auxiliary relay 73 and its contacts 73a arev opened. As previously set forth, these contacts are connected in series with the primary winding 58 of the plate transformer 5I, operating winding iiw of the holding relay Ei) and the valve opening winding S8, all of which are connected in parallel, so that they are deenergized at the end of this timeinterval. The high frequency generator 36 ceases to radiate. Since the winding 68 is deenergized, the spring ed closes the valve 63. The holding relay 60 drops and at contacts b the energizing circuit for the operating winding I2w of the line contactor I2 is opened. This contact drops and the welding circuit including the transformer i4 is deenergized. rThe system now is restored to the initially assumed condition and, on resumption of welding operations, the cycle just described is repeated. y

Since certain changes can be made in the foregoing construction and system and different embodiments of the invention can be made without departing from the spirit and scope thereof, it is intended that all matter shown in the accompanying drawing and described hereinbefore shall be interpreted as illustrative and 'not in a limit-1 ing sense.

What is claimed as new is:

1. In a system for controlling the energization of an intermittently loaded power circuit in combination, a line contactor for connecting the power circuit for energization to a current source. a start relay when deenergized providing a part of an energizing circuit for closing said line contactor and connected to be energized on short circuiting of said power circuit when said line contactor is open, a high frequency generator connected to superimpose high frequency on said power circuit and to be initiated in operation by closing .of said start relay, relay means connected to be responsive to the energization of said start relay for completing said energizing circuit for said line contactor when said start relay is deenergizing by opening said short circuit on said power circuit, and relay means connected to beA responsive to the removal of load from said power circuit for stopping further operation of said generator and for deenergizing said line contactor.

2. In a system for controlling the energization of an intermittently loaded power circuit in combination, a line contactor for connecting the power circuit for energization to a current source, a start relay connected to be energized on short ,circuiting of said power circuit when said line contactor is open, a high frequency generator connected to superimpose high frequency on said power circuit and to be initiated in operation byv closing of said start relay, a holding relay connected to be energized on closing of said start relay and arranged to effect the closure of said line contactor and to maintain said generator in operation on dropping of said start relay, and relay means connected to be responsive to the removal of load from said power circuit for stopping further operation of said generator.

3. In a system for controlling the energization of a power circuit adapted to be loaded intermittently by an arc which is arranged to be surrounded by a gaseous shielding medium, in combination, a line contactor for connecting the power circuit for energization to a current source, a start relay connected to be energized on short circuiting of said power circuit when said line contactor is open, a high frequency generator connected to superimpose high frequency on said power circuit to stabilize said arc and to be initiated in operation by closing of said start relay," valve means arranged to be opened on closure of said start relay to supply said gaseous shielding medium to the vicinity of said arc, and relay means connected to be responsive to the discontinuance of said arc for stopping further operation of said generator and effecting closure of said valve means.

4. In a system for controlling the energization of a power circuit adapted to be loaded intermittently by an arc which is arranged to be surrounded by a gaseous shielding medium, in combination,v a line contactor for connecting the power circuit for energization to a current source, a start relay connected to be energized on short circuiting of said power circuit when said line contactor is open, a high frequency generator connected to superimpose high frequency on said power circuit to stabilize said arc and to be initiated in operation by closing of said start relay, valve means arranged to be opened on closure of said start relay to supply said gaseous shielding medium to the vicinity of said arc, a holding `zr-.clayconnected :to Abe energized `er1 closing vof vsaid :start :relay r,and arranged to `eliect closure 4oifsaid:linecontactor :and lto maintain said generator inzoperation yand said valve open on droppingitof isaidzstart relay, and relay means connected te be'responsive tothev discontinuance of said arczforstopping .further operation of said generator and effecting closure Vei? said valve means.

5. In a system for controlling the energization -otfan intermittently loaded power circuit, in combination, a line contacter having an operating "wndingynormally open contacts for connecting -said .power circuit to a current source, and norfmally Aclosed contacts; a start relay having an V'operating winding connected in series with said power :circuit through said normally closed contacter contacts to a current source and energized onfshor't circuiting of said power circuit, a set of normally closed contacts and a set of normally lfopen contacts;: a high frequency generator con- A 4nected to superimpose high frequency on said power circuit and to be initiated in operationen closure ofsaid normally open start relay cenvtacts; a'holding relay having a winding connected forzenergization on .closure of said normally open :start relay `contacts and two sets of normally opencOntaCts; circuit means connecting one set otholding relay contacts in rparallel with said Anormally openstart relay contacts to maintain said generator in operation and said holding vrelay winding energized `when said start relay drops, and circuit means connecting said contacter Winding for energization to a current source lthrough said normally closed start relay Vcontacts and the other set of generator relay contacts whereby on removal of the short circuit from said power circuit said start relay drops and said normally vopen line contacter contacts VVare closed.

"6.1m a' system for controlling the energization "oan intermittently loaded power circuit, in comf'binationya line contacter having an operating winding, normally open contacts for connecting `said .power circuit-to a current source, and norma'lly'closed contacts; a start relay having an operating winding connected in series with said power circuit through said normally closed contactor contacts to a current source and energized on short circuiting of said power circuit, a `set of Ynormally closed contacts and a set of noru ma-lly open contacts; a high frequency generator connected to'superimpese high frequency on said power ycircuit-and to be initiated in operation on `closure of vsaid normally open start relay conztacts; 1a holding: relay having a winding connected for energizatien on closure of said normally openstart relay contacts and two sets of `normally'open contacts; circuit means rconnecting "onerset of holding relay contacts in parallel with said normally open start'relay contacts to maintain said generator in operation and said holding relay winding energized when said start relay drops,-circuit means connecting said contacter winding for energization to a current source through said normally closed start relay contacts V:and the other set of generator relay contacts whereby on removal of the short circuit from said power circuit lsaid start relay drops and said normally open line contacter contacts are closed, andirrelay means including normally closed con- `tacts.connected in the iirst :mentioned circuit .meanszsaid relaymeans being connected tobe responsive'ftoremoval .of load from said Ypower fcircuit to fopen, its normally closed contactsfand Vier energicatien normally closed start relay contacts and theother l0 therebystop further operation of said generator and deenergize said windings of said holding relay and contacter.

7. In a system for controlling the energization of a power circuit adapted to be loaded intermittently by an arc which is arranged to be surrounded by a gaseous shielding medium, in comnected to superimpose high frequency on said power circuit and to be initiated in operation on closure of said normally open start relay contacts; valve means arranged to be opened on closure of said normally open start relay contacts to supply `said gaseous shielding medium ,to the vicinityoi' said arc, a holding relay having a winding connected for energizationon closure of said normally open start relay contacts and two sets of normally open contacts; circuit means connecting one setfof holding relay contacts in parallel vwith said normally open-start relay contacts to maintain said generator in operation, said valve means open, and said holding relay winding energized when said start relay drops, vand circuit means connecting said contacter -winding for energization toa current source through said normally closed start relay contacts and the other set of generator relay contacts whereby on Vremoval of the short circuit from said power circuit said start relay drops and said normally open line contacter contacts are closed.

8. In a system for controlling the energization of a power circuit adapted to be loaded Aintermittently by an arc which is arranged to be surrounded by a gaseous shielding medium, in combination, a line contacter having an operating winding, normally open contacts for connecting said power circuit to a current source, and nor.- mally closed contacts; a start relay having an operating winding connected in series with said power circuit through said normally closed contacter contacts te a current source and energized on short circuiting of said power circuit, a set of normally closed contacts and a set'of normally open contacts; a high frequency generator connected to superimpose high frequency on said power circuit and to be initiated in operation on closure of said normally open start relay con.- taots; valve means arranged to be opened on closure of said normally open start relay contacts to supp-ly said gaseous shielding medium to the vicinity of said arc, a holding relay having a winding connected for energization enclosure of said normally open start relay contacts and two lsets of normally open contacts; circuit means connecting one set of holding l:clay contacts in parallel with said normally open start relay vcontacts to maintain said generator in operation, said valve means open, and said holding relay winding energized when said ystart relay drops, circuit vmeans `connecting said contacter winding vto a currentsource 'through .said

set -of generatorrelay contacts whereby on removal of the short circuit.fromsaidpewer circuit .j line start :relay Y.drops .and .said normally .open contacter contacts are closed, and relay means including normally closed contacts connected in the rst mentioned circuit means, said relay means being connected to be responsive to removal of load from said power circuit to open its normally closed contacts and thereby stop further operation of said generator, deenergize ksaid windings of said holding relay and contactor and close said valve means.

9. In a system for controlling the energization of an intermittently loaded power circuit, in combination, a transformer having a primary wind- -ing and a secondary winding connected to the power circuit, a line contactor for connecting said primary winding for energization to a current source, a first relay connected to be energized on short circuiting of said power circuit when said line contactor is open, a second relay connected to be energized on energization of said first relay and arranged on removal of said short circuit and deenergization of said first relay to energize said line contactor to supply current to a load connected across said power circuit, and a third relay connected to be responsive to the revmoval of load from said power circuit for de energizing said line contactor.

l0. The invention, as set forth in claim 9, wherein the third relay includes time delay means whereby the removal of the load for a prevdetermined interval is required before the line contactor is deenergized.

'on energization of said rst relay and arranged on removal of said short circuit and deenergization of said first relay to energize said line contactor to supply current to a load connected across said power circuit, and a third relay connected to be responsive to the removal of load from said power circuit for deenergizing said line contactor.

12. In a system for controlling the energization of an intermittently loaded power circuit. in combination. a, line contactor for connecting the power circuit for energization to a current source,

a first relay connected to be energized on short circuiting of said power circuit when said line contactor is openy a high freouency generator connected to superimpose high frequency on said power circuit and to be initiated in operation by closing of said first relay, a second relay connected to be energized on closing of said iirst relay and arranged to maintain said generator lin operation yand on removal of said short circuit and conseouent dropping of said iirst relay to energize said line contactor to supply current to a load connected across said power circuit, and 'a third relay connected to be responsive to the removal of load from said power circuit for stonping further operation of said generator and deenergizing said line contactor.

13. In a system for controlling the energization of an intermittently loaded power circuit, in combination, a line contactor for connecting the power circuit for energization to a current source and having normally closed contacts, a

Vfirst relay connected to be energized through said normally closed contacts on lshort circuitingiof said power circuit and having normally closed and normally open contacts, a second relay connected to be energized on closure of said` normally open contacts of said iirst relay on energization thereof and having two sets of normally open contacts, one of said two sets of normally open contacts being connected in parallel with said normally open contacts of said rst relay for maintaining said second relay energized and the other of said two sets of normally open contacts being connected in series with said normally closed contacts of said iirst relay for energizing said line contactor on removal of said short circuit and deenergization of said iirst relay to supply current to a load connected across said power circuit, and a third relay having normally closed contacts connected in series with said one set of normally open contacts of said second relay, said third relay being. connected to be responsive to the removal of load from said power circuit for opening its contacts to deenergize said second relay'and thereby deenergize said line contactor,

14. In a gas blanketed arc welding apparatus comprising a torch having an electrode and a nozzle, an electric circuit for passing welding current through said electrode and the work, and aconduit for passing gas to said nozzle, the improvement which comprises a valve for controlling the supply of gas to said conduit, means for operating said valve, and means responsive to voltage change in said electric circuit for actuating said valve operating means.-

l5. In a gas blanketed arc welding apparatus comprising a torch having an electrodevand a nozzle, an electric circuit for passing welding current through said electrode and the work, and a conduit for passing gas to said nozzle, the improvement which comprises a valve for controlling the supply of gas to said conduit, means responsive to arc voltage when an arc is struck between said electrode and the work for opening said valve and means responsive to open circuit voltage when said electrode is removed from the work to extinguish the arc for setting said time delay device to close said valve a predetermined time delay interval after the arc is extinguished.

16. In a gas blanketed arc welding apparatus comprising a torch having an electrode and a nozzle, an electric circuit for passing welding current through said electrode and the work, and a conduit for passing gas to said nozzle, the improvement which comprises a valve for controlling the supply of gas to said conduit, means responsive to arc voltage when the electrode is touched to the work momentarily without heating the electrode to oxidation temperature for opening said valve, said valve opening means being further responsive to arc voltage when a welding arc is struck for maintaining said valve open during the welding operation.

DEAN C. GIRARD. i

REFERENCES CITED The following references are of record in the file of this patent: 

